Modified oat and corn grit products and method

ABSTRACT

A coated, uncooked oat product is provided that has no added fat and comprises uncooked oat flakes having a coating adherent to the oat flakes. A coated, oat flake agglomerate is also provided, wherein each agglomerate comprises at least two uncooked oat flakes and has a fat-free coating. A flavored, coated oat product in bulk and a flavored, coated, agglomerated oat product are provided, both of which products have flavors uniformly distributed throughout the bulk. Corn grit products are also provided and include (1) individual pieces of corn grit having a fat-free coating and (2) clusters of corn grit pieces having a fat-free coating.

CROSS REFERENCE TO RELATED APPLICATION

This is a continuation of U.S. patent application Ser. No. 10/272,804,filed Oct. 17, 2002, which is a continuation of U.S. patent applicationSer. No. 09/737,906, filed Dec. 15, 2000, now U.S. Pat. No. ______,which is a divisional of U.S. patent application Ser. No. 09/487,036,filed Jan. 19, 2000, now U.S. Pat. No. ______.

FIELD OF THE INVENTION

This invention relates to coated, uncooked, flaked oat products andmethods of making such oat products. More particularly, the presentinvention relates to (1) an oat product comprising coated, uncooked oatflakes and having a fat-free coating adhered to the oat flakes, (2) anagglomerated oat product comprising coated, uncooked oat flakes andhaving a fat-free coating adhered thereto, (3) a flavored oat product inbulk comprising oat flakes coated with a fat-free coating, and (4) aflavored oat product in bulk comprising oat flake agglomerates having afat-free coating.

This invention also relates, in particular, to methods of making thecoated, uncooked oat flake product; the agglomerated, coated oat flakeproduct; and the coating.

BACKGROUND OF THE INVENTION

Cereal manufacturers today are faced with the ever-increasing challengeof producing flavorful yet nutritious products that appeal to consumers.Nutritionally, compared with other grains, oats offer a highconcentration of protein, a good distribution of amino acids, and fiber.Oat groats—the component of oats that is used to form oat flakes (alsotermed “flaked oats” herein)—reportedly have a high proteinconcentration in the range of about 13.8% to 25.5%. See Oat, Ch. 10 byV. L. Young and R. A. Forsberg, in “Nutritional Quality of CerealGrains: Genetic and Agronomic Improvement,” pp. 466-475, published bythe American Society of Agronomy, Inc., Madison, Wis. (1987). Moreover,the amino acid composition of oat protein is good compared to othergrains. Although lysine is the major limiting amino acid in oats, oatsstill have a higher concentration of this amino acid than is typicallyfound in other grains. Further, rolled oat groats are a good fibersource as they contain about 1.1% crude fiber and thus provide 0.3 gramsof crude fiber per ounce of rolled oat groats.

Various oat-based products—namely, granola—have been produced which takeadvantage of the high nutritional profile of the oat grain. However,because these products are produced via a baking process, they tend tohave a relatively hard texture. For that reason, granola-based productsare formulated to contain at least about 3 to 7 grams of fat per about55 grams of finished product, wherein the fat imparts a tender textureto the product. Further, in the packaged granola product, the coatingmaterial tends to chip or fall off the baked granola product and settleat the bottom of the package. As a result, it is virtually impossible toobtain a uniform, bulk-packaged, oat-based granola product.

Thus, there exists a need for an uncooked oat product comprising oatflakes and having a coating adhered to the oat product which contributesno added fat to the finished oat product. There also exists a need foran agglomerated oat product comprising agglomerated, uncooked oat flakeshaving a fat-free coating adhered to the uncooked oat flakes. Further,there exists a need for methods for making both of the aforedescribed,inventive oat products.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, a coated,uncooked oat product is provided that has no added fat and comprisesuncooked oat flakes having a coating adhering to the surface of the oatflakes. The coating comprises at least one material selected from thegroup consisting of colorants, flavors, nutrients, and sweeteners.Typically, the coating comprises from about 0.1% to about 60% by weight,on a dry weight basis of the uncooked oat product. On a dry weightbasis, the concentration of the coating is preferably in the range offrom about 5% or 20% to about 50% by weight of the uncooked oat productand most preferably, in the range of from about 35% to about 45% byweight, on a dry weight basis of the uncooked oat product.

In accordance with another aspect of the present invention, an uncookedoat product is provided comprising a coated, oat flake agglomerate,wherein each agglomerate comprises at least two uncooked oat flakes andhas a fat-free coating, as described above. In such product, the coatingcomprises from about 20% to about 60% by weight, on a dry weight basisof the oat flake agglomerate. Preferably, on a dry weight basis, thecoating accounts for about 35% to about 45% by weight of the oat flakeagglomerate.

In accordance with still another aspect of the present invention, a corngrit product is provided comprising individual pieces of corn gritcoated with the aforedescribed material which contains no added fat. Thegrits are unflaked and may be either cooked, partially cooked, oruncooked. Additionally, the coated corn grits may be clustered to formcoated clusters of corn grits in accordance with the invention. Theresulting products may be used as hot cereals.

In accordance with still another aspect of the present invention, amethod of coating uncooked oat flakes with a desired fat-free coating isprovided. The method involves feeding uncooked oat flakes into acirculating drum, coating the oat flakes by spraying the oat flakes witha stream of coating material, drying the coated oat flakes until the oatflakes have attained the desired moisture content, and cooling thecoated oat flakes. The method is additionally applicable to coatingindividual pieces of cooked or partially cooked corn grits.

In accordance with still another aspect of the present invention, amethod of forming coated, uncooked oat flake agglomerates is provided.This method involves essentially the same steps as the aforedescribedmethod for coating uncooked oat flakes. However, in the coating step ofthis method, the coating material sprayed onto the oat flakes comprisesa binder material that allows the oat flakes to form agglomerates of aplurality which may be two, three, four or more flakes and typicallyless than about 20 or 40 flakes. The method can also be used to formclusters of cooked or partially cooked corn grits.

Still another aspect of the invention relates to a method for preparingthe desired coating material in solution and/or dispersion form whichcomprises mixing together at least one component selected from the groupconsisting of colorants, flavors, nutrients, and sweeteners with waterto form a coating mixture; and optionally heating the coating mixture toelevated temperature, which can be about 140° F., for example, todissolve and/or disperse the components of the mixture and form thecoating material.

In accordance with still another aspect of the invention, a flavored oatproduct in bulk is provided, wherein the oat product in bulk comprisesuncooked oat flakes individually coated with a fat-free coating that issubstantially uniform in its distribution throughout the product.Alternatively, the coating can contain fat, if desired. Also inaccordance with the invention is a flavored oat product in bulkcomprising uncooked oat flake agglomerates of at least two oat flakeshaving a fat-free coating. The coating on these two bulk productsincludes at least one material selected from the group consisting ofcolorants, flavors, nutrients, and sweeteners and is uniformlydistributed throughout the oat product in bulk. The substantiallyuniform distribution of the coating ensures a consistent bulk-packagedproduct.

Thus, the inventive coated oat flake product, the coated oat flakeagglomerated product, the flavored oat product in bulk, the flavored,agglomerated oat product in bulk, and the methods for making suchproducts address the need for a grain product that utilizes the highprotein content of oats, contains no added fat, no significant amount ofadded fat, or added fat as desired and provides consistent productquality as the product coating does not chip or fall off the oatproduct, and exhibits good adherence to the uncooked grain or oat flake.

Products in accordance with the invention can be utilized as a hotcereal (with added milk or water and heat), a ready-to-eat cereal (withthe addition of milk) or a snack (i.e., consumed directly from thecontainer without further preparation).

Other advantages and features of the invention will become apparent fromthe following description and from reference to the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart illustrating a method of coating oat flakes witha fat-free coating material in accordance with the invention.

FIGS. 2A and 2B are flow charts illustrating a method of coating oatflakes with colorant-containing coating material in accordance with theinvention.

FIG. 3 is a flow chart illustrating a method of coating oat flakes withnutrient-containing coating material in accordance with the invention.

FIG. 4 is a flow chart illustrating a method of coating oat flakes witha butter and salt-flavored coating material in accordance with theinvention.

FIG. 5 is a flow chart illustrating a method of forming clustered,flavored oat flakes containing a vitamin/ mineral premix, in accordancewith the invention.

FIG. 6 is a flow chart illustrating a method of forming nonclustered,sweetened and flavored oat flakes in accordance with the invention.

DETAILED DESCRIPTION OF THE INVENTION

This invention includes all alternatives, modifications, and equivalentsthat may be encompassed within the spirit and scope of the invention, asdefined by the appended claims. The invention is not limited to theembodiments described herein. In accordance with the invention, anysource of oat flakes can be used and any suitable process can be used tomake oat flakes or flaked oats. It is also to be understood that inaccordance with the invention, any suitable cooking or partial cookingtechnique can be used to make corn grits. Corn grits can be obtainedfrom corn in any manner known to those skilled in the art and in anydesired size range. Throughout the following description, like numeralsand letters refer to like parts or steps.

In accordance with the present invention, an uncooked oat product isprovided which comprises uncooked, individual oat flakes having acoating that imparts no added fat to the finished product. The coatingcomprises at least one material selected from the group consisting ofcolorants, flavors, nutrients, and sweeteners. The coating, applied soit is substantially uniformly distributed over the surface of the oatproduct, preferably comprises from about 0.1% to about 60% by weight, ona dry weight basis of the uncooked oat product. More preferably, thecoating comprises from about 20% to about 50% by weight, on a dry weightbasis, of the uncooked oat product. Most preferably, the coatingcomprises from about 35% to about 45% by weight, on a dry weight basisof the uncooked oat product. Preferably, the aforedescribed inventiveproduct is packaged in a bulk quantity.

Vitamins, minerals, natural nutrients and sweeteners may be added to thecoating material if desired. Typically, vitamins are selected from thegroup consisting of, for example, vitamin A, beta-carotene, thiamin,riboflavin, niacin, vitamin B₆, vitamin B₁₂, vitamin C, vitamin D,vitamin E, folic acid, and derivatives and mixtures thereof. Mineralsare generally selected from the group consisting of, for example,calcium, copper, iron, magnesium, manganese, molybdenum, phosphorus,potassium, selenium, zinc, and derivatives and mixtures thereof. Naturalnutrients are selected from the group consisting of, for example,Echinacea extract, gingko biloba extract, ginseng, bee pollen, St.John's wort extract, and mixtures thereof. Sweeteners are generallyselected from the group consisting of, for example, sugar, fructose,honey, corn syrup, molasses, fruit juice, artificial sweeteners, andmixtures thereof.

In accordance with another aspect of the invention, the aforedescribedinventive oat product is provided wherein the oat product comprises amixture of a plurality of coated oat flakes being of a first color and aplurality of other coated oat flakes being of a second color, distinctfrom the first color. The colors are provided by water-soluble colorantspresent in the coating on the oat flakes. When the oat product is placedin contact with an aqueous medium, such as milk or water, the colorantsin the coatings of the different colored oat flakes become dissolved ordispersed and commingle in the aqueous medium to form a new color in theaqueous medium, distinct from either the first or second colors. Thus,pursuant to this embodiment, the flaked oat product forms a third, newcolor (i.e., green) where the first color is, for example, yellow andthe second, blue; (i.e., orange) where the first color is red and thesecond, yellow; or (i.e., purple) where the first color is red and thesecond, blue, for example.

In accordance with another aspect of the invention, an uncooked oatproduct is provided which comprises agglomerated, uncooked, flaked oatshaving a coating that is applied over the surface of the flaked oats andthat contributes no added fat and remains adhered to the individualflaked oats. Typically, each agglomerate comprises at least two uncookedoat flakes. The agglomerates range in size: “small” agglomerates havefrom two to ten flakes and more typically from five to ten flakes,whereas “large” agglomerates generally comprise more than ten oat flakesand, more typically, from 20 to more than 40 oat flakes.

Typically, the coating applied to the oat flake agglomerates comprisesat least one material selected from the group consisting of colorants,flavors, nutrients, and sweeteners, which are the same constituents usedin the coating that is applied to the coated, uncooked oat flakespreviously described. In addition, the coating comprises a bindingmaterial selected from the group consisting of sugar, fructose, honey,corn syrup, molasses, fruit juice, hydrocolloids, maltodextrin, cornsyrup solids, and mixtures thereof, for example. The nutrients includedin the coating of the agglomerated oat product generally are compoundsselected from the group consisting of vitamins, minerals, naturalnutrients, and mixtures thereof, as previously described.

On a dry weight basis, the coating preferably accounts for from about20% to about 60% by weight of the oat flake agglomerate and mostpreferably from about 35% to about 45% by weight of the oat flakeagglomerate. Preferably, the agglomerated oat flake product is packagedin a bulk quantity.

In another embodiment of the present invention, the agglomerated,uncooked, flaked oat product comprises a mixture of a plurality ofcolored, coated oat flakes of a first color and a plurality of colored,coated oat flakes of a second color. As described above for thenon-agglomerated oat product, the colors are produced by water-solublecolorants present in the coating, which coatings are preferably appliedin a substantially uniform manner over the surface of the oat flakes.When the agglomerated, uncooked, flaked oat product is placed in anaqueous liquid, such as milk or water as examples, and the colorantsbecome hydrated, the combination of the colorants forms a new color,distinct from the first and second colors. For example, a new color isproduced when the first color is yellow and the second, blue; when thefirst color is red and the second, yellow; or when the first color isred and the second, blue.

In yet another aspect of the invention, the uncooked, flaked oat productcomprises a mixture of a plurality of colored, coated oat flakes of afirst color and a plurality of colored, coated oat flakes of a secondcolor. As described above for the non-agglomerated oat product, thecolors are produced by water-soluble colorants present in the coating,which coatings are preferably applied in a substantially uniform mannerover the surface of the oat flakes. When the agglomerated, uncooked,flaked oat product is placed in an aqueous liquid, such as milk or wateras examples, and the colorants become hydrated, the combination of thecolorants forms a new color, distinct from the first and second colors.For example, a new color is produced when the first color is yellow andthe second, blue; when the first color is red and the second, yellow; orwhen the first color is red and the second, blue.

Also in accordance with the invention, an unflaked corn grit product isprovided wherein individual pieces of corn grit are coated with theaforedescribed coating material. In the inventive product, the coatingtypically will comprise from about 0.1% to about 40% by weight on a dryweight basis of the coated corn grit. Typically, after isolating fromcorn the grits to be processed in accordance with the invention, thegrits are cooked, partially cooked, or uncooked. Generally, cooked orpartially cooked grits would be heated and cooked prior to consumption.One known technique for cooking grits is to hydrate the grits with waterand steam. Thereafter, the grits can be dried; for example, by adrum-drying step or any other suitable means known to those skilled inthe art. After the grits are cooked, the cooked grits can be coated inaccordance with the invention and packaged until the time of theirintended use. Although not necessary, the uncooked, coated grits wouldbe cooked prior to consumption.

Another aspect of the invention is a cluster of corn grit pieces coatedwith the aforedescribed coating material. In each corn grit cluster, thecoating typically will comprise from about 0.1% to about 40% by weighton a dry weight basis of the corn grit cluster. Typically, the coatedcorn grit clusters comprise at least two individual pieces of corn gritand, more typically, from about 3 to about 20, 50, or 100 or more piecesof corn grit.

In another embodiment, both inventive corn grit products—i.e., theindividually coated corn grit product and the corn grit clusterproduct—each comprise a mixture of a plurality of coated corn gritpieces of a first color present in the coating and a plurality of othercoated corn grit pieces of a second color. As described above, thecolors are produced by water-soluble colorants present in the coating.When the mixture of coated corn grits is placed in an aqueous mediumsuch as milk or water, as examples, the colors combine to form a new,third color in the aqueous medium.

In another embodiment of the invention, a method is provided forpreparing the fat-free coating material for application onto eitherindividual uncooked oat flakes or single corn grits, comprising (i)mixing at least one component selected from the group consisting ofcolorants, flavors, nutrients, and sweeteners with water to form acoating mixture; and (ii) optionally heating the coating mixture at anelevated temperature, for example, from about 100° to 160° F., andpreferably to about 140° F., to dissolve or disperse the components ofthe coating mixture and form the coating material.

Also in accordance with the invention is a similar method of preparing acoating material for application onto either oat flake agglomerates orcorn grit clusters. This method generally comprises: (i) mixing abinding material with water and at least one component selected from thegroup consisting of colorants, flavors, nutrients, and sweeteners withwater to form a coating mixture; and (ii) optionally heating the coatingmixture to elevated temperature sufficient to dissolve or disperse thecomponents of said coating mixture and form said coating material.

In FIG. 1, a flow chart illustrates the steps involved in a method ofcoating uncooked, flaked oats with a desired, fat-free coating materialin accordance with the present invention. The method comprises: (i)feeding uncooked oat flakes; shown as stream 12, into a rotating drum;(ii) coating the oat flakes by spraying the oat flakes with a stream ofthe coating material, shown as stream 10, until the coating material isapplied over the surface of the oat flakes in a substantially uniformmanner; (iii) drying the coated oat flakes, shown as stream 14, untilthe coated oat flakes attain a desired percentage of moisture; and (iv)cooling the dried, coated, uncooked oat flakes, shown as stream 16, ifprocessed at an elevated temperature. The method also has applicationfor coating individual pieces of corn grit with a fat-free coating.

Typically, the coating and drying steps can be achieved by any suitablemeans known to those skilled in the art; for example, coating can beachieved by an enrober or rotating drum, and drying, by a continuousbelt dryer or a fluidized bed, forced air dryer. Because such devicesare well known to those skilled in the art, a detailed disclosure ofsuch equipment is not provided. Generally, the coated oat flakes aredried at a temperature in the range of from about 100° F. to about 500°F. and more typically 150-350° F. and preferably to a moisture contentof from about 3-14% and more typically 4-12%, on a dry weight basis. Thecoated corn grits are dried at a temperature in the range of from about100° F. to about 500° F. and to a moisture content of about 1-14% andmore typically about 5-7%, on a dry weight basis. The coating and dryingsteps preferably take place simultaneously.

This method efficiently distributes the coating in a substantiallyuniform manner over the surface of the flaked oats or corn grits so thatthe coating adheres to the surface of the uncooked, flaked oats or corngrits and does not readily chip or fall off the product. The resultingproduct is thus ideally suited for bulk packaging since the coatingmaterial will not separate into a separate phase or settle to the bottomof a container.

In accordance with the present invention, typically the coating materialis applied to the uncooked oat flakes at a concentration of from about0.1% to about 60%, on a dry weight basis by weight of the coated oatflakes. Preferably, on a dry weight basis, the coating material isapplied to a concentration of from about 35% to about 50% of the weightof the coated oat flakes. Preferably, with respect to corn grits, thecoating is applied, on a dry weight basis, to a concentration of fromabout 5% to about 40% by weight of the coated corn grits.

Another aspect of the present invention is a method of forming coated,uncooked oat flake agglomerates that have no added fat. The methodcomprises: (i) feeding uncooked oat flakes into a rotating drum; (ii)coating the surface of the oat flakes by spraying the oat flakes with astream of a coating material comprising a binding material until the oatflakes form agglomerates, each oat flake agglomerate comprising at leasttwo flakes; (iii) drying the oat flake agglomerates to a desiredpercentage of moisture; and (iv) cooling the coated, oat flakeagglomerates if processed at an elevated temperature. Typically, thecoating material is applied at a concentration of from about 20% to morethan 60%, on a dry weight basis by weight of the coated oat flakeagglomerates. This method is also applicable to the formation ofclusters of coated corn grit, wherein the concentration of the coatingmaterial is, on a dry weight basis, about 0.1% to about 40% or more, byweight of the coated corn grit.

The coated oat flake agglomerates typically are dried at a temperaturein the range of from about 100° F. to about 500° F. and to a desiredmoisture level, generally in the range of from about 3% to 14% and moretypically from about 4-12% on a dry weight basis. The coated corn gritclusters typically are dried at a temperature in the range of from about100° F. to about 500° F. and to a desired moisture level, generally inthe range of from about 1% to about 14% and more typically about 5-7% ona dry weight basis. Drying may be done by any suitable drying meansknown to those skilled in the art, including, for example, a continuousbelt dryer or a fluidized bed, forced air dryer.

In accordance with the invention, a flavored oat product in bulk isprovided, having flavors uniformly distributed throughout the product inbulk. The flavored oat product in bulk comprises uncooked, coated,flaked oats having a coating adhered to the flaked oats, where thecoating contributes no added fat, or added fat as desired, and includesat least one flavoring component and at least one material selected fromthe group consisting of colorants, nutrients, and sweeteners, as theseare defined above. Typically, the coating material is present on theflaked oats at a concentration of from about 0.1% to about 60% on a dryweight basis of the flavored oat product. Preferably, on a dry weightbasis, the coating material has a concentration of from about 20% toabout 50% by weight of the flavored oat product, and most preferably ata concentration of from about 35% to about 45% by weight of the flavoredoat product.

Typically, the flavored oat product in bulk comprises a mixture of aplurality of coated oat flakes of a first color and a plurality of othercoated oat flakes of a second color, distinct from the first color. Thecolor is provided by water-soluble or dispersible colorants present inthe coating of the oat flakes. When the flavored bulk oat product isplaced in an aqueous liquid, the colorants dissolve, or disperse, andcombine in the liquid to produce a new color in the liquid where the newcolor is different from the color of the dry oat flakes. For example,the colorant produces a new, third color when the first color is yellowand the second, blue; when the first color is red and the second,yellow; and when the first color is red and the second, blue.

Another embodiment of the present invention features a flavored oatproduct in bulk comprising agglomerated, coated, uncooked, flaked oats.Each agglomerate comprises at least two uncooked oat flakes. Theagglomerates range in size: “small” agglomerates have from two to tenflakes and more typically from five to ten flakes, whereas “large”agglomerates generally comprise more than ten oat flakes and, moretypically, from 20 to more than 40 oat flakes. Typically, theagglomerated, flavored oat product in bulk comprises a coating thatcontributes no added fat to the finished product and that adheres to theuncooked, flaked oats. Preferably, the coating includes at least onematerial selected from the group consisting of colorants, flavors,nutrients, and sweeteners, as these materials are described above. On adry weight basis, the coating generally comprises from about 20% toabout 60% by weight of the flavored, agglomerated, bulk oat product, andpreferably from about 35% to about 45% by weight of such product. Thesubstantially uniform distribution of coating on the flavored bulk oatproduct ensures a uniform distribution of flavors therethrough.

In accordance with another aspect of this invention, the flavored bulkoat product is a mixture of a plurality of coated oat flake agglomeratesof a first color and a plurality of coated oat flake agglomerates of asecond color, consistent with the description given above. Water-solubleor dispersible colorants present in the coatings impart the color to thecoated oat flake agglomerates. When the flavored bulk oat product isplaced in an aqueous liquid, the colorants cause the liquid to develop anew, third color, distinct from the first and second colors. Forexample, the colorants produce a green color when the first and secondcolors are yellow and blue; they produce orange when the first andsecond colors are red and yellow, and purple when the first and secondcolors are red and blue.

The following are examples of embodiments of the inventive method as itmay be used to produce a variety of coated oat flake products or coatedcorn grit products.

The coating and drying steps utilize equipment that is well known tothose skilled in the art. However, examples of particular systems thatare suitable include a system that provides simultaneous coating anddrying, designated as PSC-020 Batch Coating System, manufactured byCoating Machinery Systems, Inc. of Huxley, Iowa.

The process of the present invention can be operated as a batch orcontinuous process. To prevent unwanted agglomeration or clumping, thecoated oat flakes can be agitated during drying and/or cooling.

EXAMPLE 1

As described below, the inventive method is suited for making abulk-packaged, colored oat flake product that, when cooked, can beserved as oatmeal.

The process, shown in FIG. 2A, commences with feeding stream 14′ whichcan be either a batch or continuous process comprising 1 kilogram of oatflakes into a drum D rotating at a speed of 17 RPM. A coating material,designated as stream 12′, is prepared by mixing stream 10′ comprising2.5 grams of, for example, red colorant (or any other colorant) with 250grams of water in a blender B until thoroughly dispersed or dissolved.Approximately 167-250 grams of coating material, stream 12′, is sprayedonto the oat flakes, and drum D is rotated until the coating material issubstantially uniformly applied over the surface of the oat flakes. Thecoated oat flakes, shown as stream 16′, can be dried either on a batchor continuous basis. The coated oat flakes are dried in dryer O at 200°F. for about 1.6 minutes, 50% of which time includes exposure to avertically directed air flow. The coated and dried oat flakes, shown asstream 18, are then cooled to a temperature of less than 110° F. Thefinished colored oat flake product, shown as stream 20, typically has amoisture concentration in the range of about 9 to 12%.

This method may be used to prepare oat flakes that are of virtually anycolor, such as red, green, blue, yellow, orange, blue/yellow,multi-colored, and variations thereof, for example.

In another embodiment, the inventive method may be used to prepare amulti-colored oat flake product, comprising a mixture of colored oatflakes. Shown in FIG. 2B, this method involves mixing concentrations ofoat flakes of a first color, shown as stream 22, with oat flakes of asecond color, shown as stream 24, so as to produce a finished product,stream 26, containing a mixture of colored oat flakes in desiredconcentrations. For example, blue oat flakes and red oat flakes can bemixed together in a concentration of 40:60. This embodiment is notlimited to the use of only two colors of oat flakes; alternatively,three, four, five or more colors of oat flakes can be blended togetherto achieve a finished product with the desired color combination andconcentration. Any suitable device, such as a rotating drum, may be usedto blend the colored oat flakes to achieve a substantially uniformlymixed product.

Colored oatmeal may be prepared from the colored oat flake product bycombining the oat flakes with a desired amount of milk or water andcooking the mixture in a suitable manner.

EXAMPLE 2

The method of Example 1 may be modified and utilized, as shown in FIG.3, to form a nutrient-fortified oat flake product. Here, the coatingmaterial is prepared by blending 100 grams of water and 0.5 grams of thedesired nutrient, shown as stream 30, in a blender B. In this case, thenutrient used is a blend of vitamins B₆, B₁₂ and folate. The coatingmaterial, shown as stream 32, is sprayed onto 1 kilogram of oat flakes,shown as stream 34, as they tumble in a drum D that is rotating at 17RPM. The tumbling action of the oat flakes helps to uniformly dispersethe coating material in a substantially uniform manner across thesurface of the oat flakes. Shown as stream 36, the coated oat flakes arethen spread to a depth of about 1 to 3 inches and dried at 200° F. forabout 2-4 minutes. Approximately 50% of the drying time utilizes avertically directed air flow. The dried, coated oat flakes, shown asstream 38, are then cooled to a temperature of less than 110° F. Thefinished, nutrient-fortified oat flake product, stream 40 in FIG. 3, hasa moisture concentration of about 10% to 13%.

This method may be used to fortify oat flake products with vitamin Bderivatives such as vitamins B₆ and B₁₂, as well as ginseng, Echinaceaextract, and gingko biloba extract, for example.

EXAMPLE 3

FIG. 4 shows a method for producing a savory, bulk-packaged oat flakeproduct having a butter and salt flavor. In this example, the coatingmaterial is prepared by blending ingredients, shown as stream 50, whichinclude 7.5 grams of butter flavor, 15 grams of salt (optional), and 100grams of water in a blender B. The coating material, stream 52, isapplied with a spray gun G onto 1 kilogram of oat flakes, shown asstream 54, contained in a rotating drum D that is rotating at 17 RPM.The tumbling action of the oat flakes facilitates the distribution ofthe coating material so it becomes substantially uniformly distributedacross the surface of the oat flakes. The coated oat flakes, shown asstream 56, are first dried to yield stream 58—i.e., dried, coated oatflakes having a desired moisture concentration. The dried, coated oatflakes are then cooled under the same conditions given in Example 2above. The finished oat flake product, shown as stream 59, has amoisture concentration of about 10% to 13%.

The inventive method may be used to prepare oat flake products having avariety of flavors, such as vanilla, malt, peanut butter, and caramelnut, as examples.

EXAMPLE 4

Shown in FIG. 5 is a method for producing a bulk-packaged, clustered oatflake product that has a maple, brown sugar flavor and is suitable forconsumption in any one of three ways; i.e., as a ready-to-eat cereal, ahot cereal, or a snack. The coating material is prepared by blending 621grams of liquid sugar, 18.5 grams of brown sugar, and 5.3 grams of mapleflavor with 39.1 grams of a premix comprising salt, guar gum, vitaminsand minerals, these ingredients being shown as stream 60. As with theprevious examples, these ingredients are typically mixed in a blender Bto yield a coating mixture, shown as stream 62. After coating mixture 62is heated to about 140° F., the resulting coating material, shown asstream 64, is applied to 1 kilogram of oat flakes, shown as stream 66,contained in a drum D rotating at 17 RPM. A spray gun G, connected to anair line having 10 psi, is used to apply coating material, stream 64, at5 psi to the oat flakes as they tumble in rotating drum D. The coatedoat flakes, shown as stream 68, are spread to a depth of about 1 to 3inches and dried at 270° F. for about 6 minutes. For 50% of the dryingtime, the oat flakes are subjected to an up/down air flow. The driedflakes, depicted as stream 70, are then cooled, as they are stirred, toa temperature of less than 110° F. The finished product, shown as stream72, has a moisture concentration of about 4.9%.

Examples of other oat flake products that can be prepared via thismethod are brown sugar-cinnamon-flavored and coffee-flavored oat flakes,although the method can be used to apply essentially any type of flavor.

EXAMPLE 5

FIG. 6 illustrates a method for producing nonclustered, sweetened andflavored oat flakes. In this embodiment of the invention, the methodfeatures concurrent coating and drying steps. The coating material isprepared by blending 4.13 kilograms of sugar with 3.0 kilograms ofwater, and adding from about 19.3 to about 32.1 grams of flavor and213.4 grams of salt. The ingredients are shown as stream 80 in FIG. 6.The mixture, shown as stream 82, is heated to about 100-160° F., andmore preferably 120° F., to promote dissolution of the solids and formthe coating material, shown as stream 84. A spray gun G is used todispense about 1.27 kilograms of the coating material, shown as stream84, under 10 psi, onto 1.82 kilograms of oat flakes that are tumbling ina rotating drum D at a speed of 12 RPM. The oat flakes are shown asstream 86. The atomizing air for spray gun G is generally in the rangeof about 6-12 psi, and the coating step takes about 6 minutes. Thecoated flakes are dried at a temperature of about 270° F. for asufficient amount of time to achieve drying. During coating and drying,the air flow is about 850 cfm. The dried oat flakes, shown as stream 88,are then cooled for about 2.5 minutes. Shown as stream 90, the finishedproduct has a moisture concentration in the range of about 7.5%.

As described above, this embodiment of the invention can be used toprepare nonagglomerated oat flakes coated with a variety of flavors andsweeteners, such as brown sugar, cinnamon, or maple flavors, forexample.

While the invention has been described with respect to certain preferredembodiments, it is to be understood that the invention is capable ofnumerous changes, modifications, and rearrangements without departingfrom the scope or spirit of the invention as defined in the claims.

1. A bulk packaged uncooked oat flake food product containing no grainother than oats comprising: grain composed only of a bulk quantity ofindividual, separate uncooked oat flakes, each of the uncooked oatflakes coated with a fat-free adherent coating that adheres to thesurface of the uncooked oat flakes the coating composed of coatingmaterial comprising a binder and an active ingredient different from thebinder and uniformly dispersed within the binder selected from the groupconsisting of vitamins, natural nutrients, sweeteners, flavors andcolorants; and a bulk container containing the bulk quantity of coateduncooked oat flakes wherein substantially none of the coating materialsettles to the bottom of the container.
 2. The product of claim 1wherein said coating material comprises from about 0.1% to about 60% byweight, on a dry weight basis of the coated, uncooked oat product. 3.The product of claim 1 wherein said coating material comprises fromabout 20% to about 50% by weight, on a dry weight basis of the coated,uncooked oat product.
 4. The product of claim 1 wherein said coatingmaterial comprises from about 35% to about 45% by weight, on a dryweight basis of the coated, uncooked oat product.
 5. The packaged foodproduct of claim 1 wherein the coating material comprises at least onematerial selected from the group consisting of colorants, flavors,nutrients and sweeteners.
 6. The product of claim 5 wherein saidnutrients include compounds selected from the group consisting ofvitamins, natural nutrients, and mixtures thereof.
 7. The product ofclaim 6 wherein said vitamins are selected from the group consisting ofderivatives of vitamin A, beta-carotene, thiamin, riboflavin, niacin,vitamin B₆, vitamin B₁₂, vitamin C, vitamin D, vitamin E, folic acid,and mixtures thereof.
 8. The product of claim 6 wherein said naturalnutrients are selected from the group consisting of Echinacea extract,gingko biloba extract, ginseng, bee pollen, St. John's wort extract, andmixtures thereof.
 9. The product of claim 5 wherein said sweeteners areselected from the group consisting of sugar, fructose, honey, cornsyrup, molasses, fruit juice, artificial sweeteners, and mixturesthereof.
 10. An uncooked, oat product containing no grain other thanoats comprising: grain composed only of a bulk quantity of individual,separate uncooked oat flakes, each of the uncooked oat flakes coatedwith a fat-free adherent coating that adheres to the surface of theuncooked oat flakes, the coating composed of coating material comprisinga binder and an active ingredient different from the binder anduniformly dispersed within the binder selected from the group consistingof vitamins, natural nutrients, sweeteners, flavors and colorants, thecoating comprising at least one material selected from the groupconsisting of colorants, flavors, nutrients, and sweeteners.
 11. Theproduct of claim 10 wherein said coating material comprises from about20% to about 60% by weight, on a dry weight basis of the coated,uncooked oat flake agglomerate.
 12. The product of claim 10 wherein saidcoating material comprises from about 35% to about 45% by weight, on adry weight basis of the coated, uncooked oat flake agglomerate.
 13. Theproduct of claim 10 wherein said agglomerate comprises from two to tenoat flakes.
 14. The product of claim 10 wherein said agglomeratecomprises more than ten oat flakes.
 15. The product of claim 10 whereinsaid nutrients include compounds selected from the group consisting ofvitamins, natural nutrients, and mixtures thereof.
 16. The product ofclaim 15 wherein said vitamins are selected from the group consisting ofderivatives of vitamin A, beta-carotene, thiamin, riboflavin, niacin,vitamin B₆, vitamin B₁₂, vitamin C, vitamin D, vitamin E, folic acid,and mixtures thereof.
 17. The product of claim 15 wherein said naturalnutrients are selected from the group consisting of Echinacea extract,gingko biloba extract, ginseng, bee pollen, St. John's wort extract, andmixtures thereof.
 18. The product of claim 9 wherein said sweeteners areselected from the group consisting of sugar, fructose, honey, cornsyrup, molasses, fruit juice, artificial sweeteners, and mixturesthereof.
 19. The packaged food product of claim 18 wherein the fat-freematerial comprises at least one material selected from the groupconsisting of colorants, flavors, nutrients and sweeteners.
 20. Thepackaged food product of claim 19 wherein said at least one material isuniformly distributed throughout the bulk quantity of coated uncookedoat flake agglomerates.
 21. A packaged uncooked oat flake food productcontaining no grain other than oats comprising: a grain componentcomposed solely of uncooked oat flakes, the grain component coated witha fat-free coating material that is present as an adherent coating thatadheres to the surface of the uncooked oat flakes to form a bulkquantity of coated uncooked oat flake agglomerates, and a bulk containerfor packaging the bulk quantity of coated oat flake agglomerates whereinsubstantially no coating material settles to the bottom of thecontainer.
 22. The packaged food product of claim 21 wherein saidcoating material comprises from about 20% to about 60% by weight, on adry weight basis of the bulk quantity of coated uncooked oat flakeagglomerates.
 23. The packaged food product of claim 21 wherein saidcoating material comprises from about 35% to about 45% by weight, on adry weight basis of the bulk quantity of coated uncooked oat flakeagglomerates.
 24. The packaged food product of claim 21 wherein saidagglomerate comprises from two to ten flakes.
 25. The packaged foodproduct of claim 21 wherein said agglomerate comprises more than ten oatflakes.
 26. The packaged food product of claim 21 wherein saidagglomerate comprises from 20 oat flakes to more than 40 oat flakes. 27.The packaged food product of claim 21 wherein the bulk quantity ofcoated uncooked oat flake agglomerates further comprises a mixture of aplurality of coated oat agglomerates of a first color and a plurality ofcoated oat agglomerates of a second color distinct from the first color.28. The packaged food product of claim 27 wherein when said product isplaced in an aqueous liquid, a new color is formed in said liquid from acombination of said first and second colors.
 29. The packaged foodproduct of claim 19 wherein said nutrients include compounds selectedfrom the group consisting of vitamins, minerals, natural nutrients, andmixtures thereof.
 30. The packaged food product of claim 29 wherein saidvitamins are selected from the group consisting of derivatives ofvitamin A, beta-carotene, thiamin, riboflavin, niacin, vitamin B₆,vitamin B₁₂, vitamin C, vitamin D, vitamin E, folic acid, and mixturesthereof.
 31. The packaged food product of claim 29 wherein said mineralsare selected from the group consisting of derivatives of calcium,copper, iron, magnesium, manganese, molybdenum, phosphorus, potassium,selenium, zinc, and mixtures thereof.
 32. The packaged food product ofclaim 29 wherein said natural nutrients are selected from the groupconsisting of Echinacea extract, gingko biloba extract, ginseng, beepollen, St. John's wort extract, and mixtures thereof.
 33. The packagedfood product of claim 19 wherein said sweeteners are selected from thegroup consisting of sugar, fructose, honey, corn syrup, molasses, fruitjuice, artificial sweeteners, and mixtures thereof.
 34. The product ofclaim 19 wherein said coating material is applied in a substantiallyuniform manner to the surface of the oat flakes.
 35. The packaged foodproduct of claim 1 wherein the coated oat flakes are uniformly coatedwith the fat-free coating material.
 36. The packaged food product ofclaim 5 wherein substantially all the coating material adheres to theoat flakes in the bulk container and wherein the food product is aflavored oatmeal and the flavor material is contained in the fat-freecoating material.
 37. The packaged food product of claim 5 wherein thebulk quantity of coated uncooked oat flakes further comprises a mixtureof a plurality of coated oat flakes of a first color and a plurality ofcoated oat flakes of a second color distinct from the first color.
 38. Amethod of preparing a packaged and coated uncooked oat flake foodproduct containing no grain other than oats comprising: coating a graincomponent composed solely of uncooked oat flakes with a fat-free coatingmaterial that is present as an adherent coating that adheres to thesurface of the uncooked oat flakes to form a bulk quantity ofindividually coated uncooked oat flakes; drying the bulk quantity ofcoated uncooked oat flakes until the oat flakes attain a desiredmoisture content; and packaging the bulk quantity of coated uncooked oatflakes in a bulk container wherein substantially no coating materialsettles to the bottom of the bulk container.
 39. The method of claim 38further comprising uniformly distributing a component selected from thegroup consisting of colorants, nutrients, sweeteners, and combinationsthereof throughout the bulk quantity of coated oat flakes by formingsaid coating.
 40. The method of claim 38 further comprising mixing aplurality of coated oat flakes of a first color with a plurality ofcoated oat flakes of a second color distinct from the first color toform a multi-colored bulk quantity of coated oat flakes.
 41. A method ofpreparing a packaged and coated uncooked oat flake food productcontaining no grain other than oats comprising: coating a graincomponent composed solely of uncooked oat flakes with a fat-freeadherent coating material that adheres to the surface of the uncookedoat flakes; mixing the coated oat flakes so that there is contactbetween at least some of the flakes to form a bulk quantity of discretecoated uncooked oat flake agglomerates; drying the plurality of oatflake agglomerates until the oat flake agglomerates attain a desiredmoisture content to form coated uncooked oat flake agglomerates; andpackaging the bulk quantity of coated uncooked oat flake agglomerates ina bulk container wherein substantially no coating material settles tothe bottom of the container.